Methods of spraying multi-component liquids

Abstract

Methods of applying multi-component liquid sprays are described. The methods include using the first array of first component spray orifices to produce a first spray of the first liquid; using the second array of second component spray orifices to produce a second spray of the second liquid; and mixing at least a portion of the first spray and at least a portion of second spray.

1 . A method of producing a multi-component spray comprising: 
 delivering a first liquid comprising a first component and a second liquid comprising a second component to a multi-component liquid spray system, wherein the multi-component liquid spray system comprises a first array of first component spray orifices and a second array of second component spray orifices;    using the first array of first component spray orifices to produce a first spray of the first liquid;    using the second array of second component spray orifices to produce a second spray of the second liquid; and    mixing at least a portion of the first spray and at least a portion of second spray.    
   
   
       2 . The method of  claim 1 , wherein the first array of first component spray orifices is a first linear array, and wherein the second array of second component spray orifices is a second linear array.  
   
   
       3 . The method of  claim 2 , wherein the first linear array of first component spray nozzles is co-aligned with the second linear array of second component spray nozzles.  
   
   
       4 . The method of  claim 2 , where in the first linear array of first component spray nozzles is parallel to the second linear array of second component spray nozzles.  
   
   
       5 . The method of  claim 1 , further comprising 
 delivering a third liquid comprising a third component to the multi-component liquid spray system, wherein the multi-component liquid spray system further comprises a third array of third component spray orifices;    using the third array of third component spray orifices to produce a third spray of the third liquid; and    mixing at least a portion of the third spray and at least a portion of the first and second sprays.    
   
   
       6 . The method of  claim 1 , wherein using the first array of first component spray orifices to produce the first spray of the first component comprises urging the first liquid through a first array of first component spray nozzles, wherein each of the first component spray nozzles comprises a first component exit orifice, and ejecting the first liquid from the first array of first component spray orifices; and wherein using the second array of second component spray orifices to produce the second spray of the second liquid comprises urging the second liquid through a second array of second component spray nozzles, wherein each of the second component spray nozzles comprises a second component exit orifice, and ejecting the second liquid from the second array of second component spray orifices.  
   
   
       7 . The method of  claim 6 , wherein each of the first component spray nozzles comprises a primary flow axis, and wherein the first component spray orifice of each first component spray nozzle is beveled at an angle of between 15° and  60 ° relative to the primary flow axis of its nozzle.  
   
   
       8 . The method of  claim 6 , wherein the first array of first component spray nozzles is a first linear array, and the second array of second component spray nozzles is a second linear array, and wherein the first linear array of first component spray nozzles is co-aligned with the second linear array of second component spray nozzles.  
   
   
       9 . The method of  claim 8 , wherein the center-to-center distance between each first component spray nozzle and its nearest second component spray nozzle is no greater than ten times the mean hydraulic diameter of the exit orifice of the first component spray nozzle.  
   
   
       10 . The method of  claim 6 , wherein the first array of first component spray nozzles is a first linear array, and the second array of second component spray nozzles is a second linear array, and wherein the first linear array of first component spray nozzles is parallel to the second linear array of second component spray nozzles.  
   
   
       11 . The method of  claim 10 , wherein the center-to-center distance between each first component spray nozzle and its nearest second component spray nozzles is no greater than ten times the mean hydraulic diameter of the exit orifice of the first component spray nozzle.  
   
   
       12 . The method of  claim 10 , wherein each of the second component spray nozzles is offset from its nearest first component spray nozzle, optionally wherein each of the second component spray nozzles is offset from its nearest first component spray nozzle by at least 40% of the distance between adjacent first component spray nozzles.  
   
   
       13 . The method of  claim 6 , wherein the multi-component liquid spray system further comprises an air chamber bounded on one side by a member comprising a plurality of air orifices, wherein each of the first component spray nozzles protrudes through an air orifice, and wherein using the first array of first component spray orifices to produce the first spray of the first liquid further comprises urging air from the air chamber, through the air orifices, and contacting the air with the first liquid after it exits the first component spray orifices.  
   
   
       14 . The method of  claim 1 , wherein the multi-component liquid spray system comprises a housing comprising a first die portion and a second die portion, and a shim comprising a first array of first liquid passages and a second array of second liquid passages, wherein at least one of the second liquid passages is located between successive first liquid passages; and wherein the shim is positioned between the first and second die portions of the housing forming a first array of first liquid conduits corresponding to the first array of first liquid passages, wherein each of the first liquid conduits terminates in a first component spray orifice; and a second array of second liquid conduits corresponding to the second array of second liquid passages, wherein each of the second liquid conduits terminates in a second component spray orifice.  
   
   
       15 . The method of  claim 14 , wherein using the first array of first component spray orifices to produce the first spray of the first liquid comprises urging the first liquid through the plurality of first liquid conduits, and ejecting the first liquid from the first liquid orifices, and wherein using the second array of second component spray orifices to produce the second spray of the second liquid comprises urging the second liquid through the plurality of second liquid conduits, and ejecting the second liquid from the second liquid orifices.  
   
   
       16 . The method of  claim 15 , wherein the multi-component liquid spray system further comprises a first air knife comprising an exit slot located proximate the first liquid orifices, wherein using the first array of first component spray orifices to produce the first spray of the first liquid further comprises urging air through the air knife exit slot and contacting the air with the first liquid after it exits the first component spray orifices.  
   
   
       17 . The method of  claim 15 , wherein the shim further comprises a third array of third passages; wherein the shim is positioned between the first and second portions of the housing forming a third array of air conduits corresponding to the third array of third passages, and wherein at least one air conduit is interspersed between adjacent first and second liquid conduits, and wherein using the first array of first component spray orifices to produce the first spray of the first liquid further comprises urging air through the third array of air conduits and contacting the air with the first liquid after it exits the first component spray orifices.  
   
   
       18 . A method of making a coated article comprising: 
 delivering a first liquid comprising a first component and a second liquid comprising a second component to a multi-component liquid spray system, wherein the multi-component liquid spray system comprises a first array of first component spray orifices and a second array of second component spray orifices;    using the first array of first component spray orifices to produce a first spray of the first liquid;    using the second array of second component spray orifices to produce a second spray of the second liquid; and    impinging the first and second sprays on an article; wherein at least a portion of the first spray and the second spray are mixed before impinging on the article.    
   
   
       19 . The method of  claim 18 , wherein using the first array of first component spray orifices to produce the first spray of the first liquid comprises urging the first liquid through a first array of first component spray nozzles, wherein each of the first component spray nozzles comprises a first component exit orifice, and ejecting the first liquid from the first array of first component spray orifices; and wherein using the second array of second component spray orifices to produce the second spray of the second liquid comprises urging the second liquid through a second array of second component spray nozzles, wherein each of the second component spray nozzles comprises a second component exit orifice, and ejecting the second liquid from the second array of second component spray orifices.  
   
   
       20 . The method of  claim 18 , wherein the multi-component liquid spray system comprises a housing comprising a first portion and a second portion, and a shim comprising a first array of first liquid passages and a second array of second liquid passages, wherein at least one of the second liquid passages is located between successive first liquid passages; and wherein the shim is positioned between the first and second portions of the housing forming a first array of first liquid conduits corresponding to the first array of first liquid passages, wherein each of the first liquid conduits terminates in a first component spray orifice; and a second array of second liquid conduits corresponding to the second array of second liquid passages, wherein each of the second liquid conduits terminates in a second component spray orifice.  
   
   
       21 . The method of  claim 20 , wherein using the first array of first component spray orifices to produce the first spray of the first liquid comprises urging the first liquid through the plurality of first liquid conduits, and ejecting the first liquid from the first liquid orifices, and wherein using the second array of second component spray orifices to produce the second spray of the second liquid comprises urging the second liquid through the plurality of second liquid conduits, and ejecting the second liquid from the second liquid orifices.